When I laid out the sides I marked the door cut out, which should show through the fiberglass. Using a jig saw I cut out the window first, then the door.
Now I need to build a lip for the door to seal on. Andrew made this drawing (thanks Andrew). The purple (maybe it is blue) is the body. I am adding two pieces, an 1/8" spacer, to give room for the seal (black in the illustration) and the lip.
Due to the complex shape, I built the spacer out of many small pieces. Each piece is custom fit and goes all the way back to the interior spar. Cut out the general shape and held it in place and drew the curve, cut out with jig saw, glue and clamp. Do not make more than you can clamp. Let dry overnight, remove clamps and sand for exact shape. I made the lip out of two layers of 5.2mm ply (I have no idea where it came from, but it is nice thin ply). The lip is 3/4". Do not put the seams in the same place. This took about a week of clamping, letting the glue dry, cutting a piece to go over it, gluing, clamping.....
After sanding, coat the entire thing with fiberglass resin.del
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